Fastening Device

ABSTRACT

A fastener, such as a staple, includes a body having a bridge portion, a first leg, and a second leg. The body extends along an axial direction. Each of the first and second legs has an inner surface and an outer surface. The inner surfaces of the first and second legs are disposed in facing relation to define a distance therebetween. In one embodiment, the distance decreases along the axial direction in a direction towards the bridge portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims the benefit of U.S. Provisional Patent Application No. 62/587,597, filed on Nov. 17, 2017, and U.S. Provisional Patent Application No. 62/667,678, filed on May 7, 2018, both of which are incorporated herein in their entirety by this reference.

FIELD OF THE DISCLOSURE

The disclosure relates to fasteners, and, more particularly, to staples.

BACKGROUND OF THE DISCLOSURE

Powered fastening devices are commonly used by homeowners and contractors and are chiefly designed to drive standardized light fasteners into untreated wood. In the electrical utility field, it is common for typical users of powered fastening devices to affix cables or wires with large staples to utility poles and other structural members of an electrical distribution system, often in remote locations where standard line power sources are unavailable. Currently, the preferred method of accomplishing this task is to use a common hammer to drive U-shaped nails or staples into these structural members. The use of a hammer to strike the rounded strike surface of typical stapling fasteners in the prior art is prone to being mishit or deformed by the fastening device, potentially causing damage or inaccurate fastening. There exists in this field a need for fastening devices and stapling fasteners better suited to these tasks.

A typical powered fastening device in the prior art is designed to aggressively drive a fastener into a medium as deep and as quickly as possible, usually in a single stroke, however this is disadvantageous in some applications, including electrical utility work. In these applications, a heavy duty stapling fastener is used to affix and guide a delicate elongated object, such as a wire or a wire chase, to a working surface, and excessive force may damage or sever the wire or wire chase. An inaccurate insulation can also cause bowing or bending of the wire or wire chase, requiring the removal and reinstallation of the stapling fastener.

Additionally, many modern utility poles and other structural members found in the power utility trade are hardened, which may requiring more strokes than current standard battery operated fastening devices provide to drive large stapling fasteners. Accordingly, a multiple-strike electrically powered fastening device is preferable for this application to incrementally, but rapidly, drive a stapling fastener into a utility pole.

BRIEF SUMMARY OF THE DISCLOSURE

In general, the present disclosure is directed to a fastening system and, more particularly, a staple fastener for use to attached wires, conduits, channels and other structures onto utility poles. For example, to protect and secure destructible items onto wooden utility poles, a few embodiments of a modified stapling fastener are disclosed. Features of the stapling fastener can include an interior cutout conforming to a wire, an interior profile conforming to a wire chase, a broad-headed striking area to maximize contact between the fastener and a drive pin, where this striking area is parallel to the end of the driving pin to ensure perpendicular placement of the stapling fastener into a working surface, barbs disposed along fastening portions of the staple, a non-uniform cross sectional area of the portions of the fastener that are embedded into the wood, and other features.

In one aspect, the disclosure describes a staple. The staple includes a first leg extending between a first tip and a first striking surface, the first leg having a width. A second leg extends between a second tip and a second striking surface. A bridge portion is disposed between the first and second legs, axially at a location between the first and second legs. The width of the first leg generally increases over at least a portion of the first leg in an axial direction from the first tip towards the first striking surface.

In another aspect, the disclosure describes a body having first and second legs connected at a striking end, each of the a first and second legs extending between a respective tip and a respective striking surface at the striking end. Each of the first and second legs has an inner surface and an outer surface, the inner surfaces converging at least partially along a length of each of the first and second legs such than a distance between the first and second legs gradually decreases over at least the portion of the body near the bridge portion. The outer surfaces of the first and second legs are substantially parallel to one another and to the axial direction along said length.

In yet another aspect, the disclosure describes a staple that includes a first leg extending between a first tip and a first striking surface, a second leg extending between a second tip and a second striking surface, the second leg being oriented such that the first and second tips are adjacent and the first and second striking surfaces are adjacent in an axial direction, and a bridge extending between the first and second legs, the bridge axially disposed between the first and second tips and the first and second striking surfaces. Each of the first and second legs has an inner surface and an outer surface. The inner surfaces of the first and second legs converge at an area near the bridge portion to define, together, concave features of different radii within the body between the first and second legs, the different radii being axially aligned.

In yet another aspect, the disclosure describes a staple having first and second legs extending substantially in parallel in an axial direction, each extending between a respective tip and a respective striking surface. The staple further includes a bridge connected to the first and second legs between the two respective tips and the two respective striking surfaces. The two respective striking surfaces are coplanar and perpendicular to the axial direction. Each of the first and second legs has an inner surface and an outer surface. The outer surfaces of the first and second legs are parallel and perpendicular to the two respective striking surfaces. The inner surfaces of the first and second legs are disposed in facing relation to define a distance therebetween that decreases along the axial direction in a direction towards the bridge portion.

In yet another aspect, the disclosure describes first and second legs, each extending between a respective tip and a respective striking surface along an axial direction. The striking surfaces of the first and second legs are coplanar, and each of the first and second legs has a width. A bridge portion is disposed between the first and second legs. The bridge is disposed axially at a location between the striking surfaces and the tips of the legs. The width of each of the first and second legs generally increases over a substantial length thereof in a direction towards the bridge portion.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

FIG. 1 is a perspective view of one embodiment for an impact device in accordance with the disclosure.

FIGS. 2 and 3 are perspective views of a staple in accordance with the disclosure.

FIG. 4 is an outline view of an alternative embodiment for a staple in accordance with the disclosure.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

The present disclosure relates to an impact tool and, more specifically, to a staple fastener for use with the impact tool. The staples described herein are relatively large staples used to fasten conduits and various other structures such as wire channels and rods to wooden utility poles.

An impact device or stapler 100 is shown in FIG. 1. The stapler 100 housing 102 that operatively contains a drive mechanism 104, an impact-mechanism 106, and a staple-driving mechanism 108, which are contained within the housing 102. The stapler 100 further includes a handle 110 that includes a trigger 112 for operating the impact-mechanism and drive staples into a work-piece. A fastener housing 114 is attached to the housing 102 and is adapted to include a plurality of staples 200, which are dispensed, one at a time, during use. In the illustrated embodiment, the staples 200 may be dispensed from a clip or magazine contained within the fastener housing 114.

One embodiment for the staple 200 is shown in FIGS. 2 and 3. In reference to these figures, it can be seen that the staple 200 may be constructed by an appropriate operation, for example, a punching operation to cut out the staple from a plate material having a thickness, T; a forging operation to form the staple from a preform, or the like. The staple 200 includes an elongate bridge 202 connected at either end to legs 204. While the legs 204 are of equal length in the embodiment for the staple 200 shown in FIGS. 1-3, one of the legs 204′ may be shorter than the other leg 204 in an alternative embodiment for a staple 200′ shown in FIG. 4.

Each of the legs 204 has an elongate shape having a tip 206 at one end and a striking surface 45 at another end. A bridge 202 as shown extends between the two legs 204 at a top portion thereof in an area adjacent to the striking surfaces 45. As can be appreciated, the driving force to install the fastener by sinking the two legs 204 into a material such as wood is applied to the striking surfaces 45. To ensure proper force application, the bridge 202 is disposed lower or offset at a location between the striking surfaces 45 and the tips 206, but in other embodiments it may be flush with the striking surfaces 45. The striking surfaces 45 are coplanar and parallel to a plane, P, which is defined by the tips 206 of the legs 204. As constructed, the tips 206 define a footprint area 208 onto the surface in which the staple 200 will be fastened. The footprint area 208 is at least as large as an area 210 defined between the two striking surfaces 45, and the areas 208 and 210 are axially aligned and overlap with respect to an axial direction, L, along which the staple 200 is driven into a workpiece. The striking surfaces 45 are oriented perpendicular to the axial direction L such that an impact loading applied to the staple 200 by a hammer (not shown) within the stapler 100 (FIG. 1), which loading is applied along the axial direction L onto the striking surfaces 45, is transferred into the surface in which the staple 200 is driven.

Each of the legs 204 has a non-uniform cross section or width in the axial direction, which provides an improved retention force when the staple 200 is fastened, especially in a wooden utility pole. More specifically, each leg 204 includes a tip portion 52, which is beveled to either a rounded point 212, as shown in FIGS. 2 and 3, or to a sharp point 214, as shown in FIGS. 1 and 4. In the embodiment shown in FIG. 3, each leg 204 includes a generally straight portion 216 having a uniform width, W, adjacent the tip portion 52. This means that a distance, D, between the two facing sides or, stated differently, inner edges 218 of the legs 204 is generally uniform in an axial direction over the straight portion 216. The straight portion 216 aids in the initial penetration of the work piece by the staple 200, and stabilizes the staple 200 so a straight insertion can more easily be achieved.

Adjacent the straight portion 216, each leg 204 includes a tapered portion 220. Over the tapered portion 220, each leg has a gradually increasing width. In the embodiment shown, each leg 204 includes an outer surface 226. The two outer surfaces 226 define planes that are parallel to one another and to the longitudinal axis L. The inner edge 218 of each leg 204 tapers inwardly such that the width W or each foot 204 increases and the distance D between the two legs decreases in an axial direction towards the bridge 202. The shape of the inner edge 218 over the tapered portion 220 may assume any desired shape. For example, and as shown in FIG. 3, the inner edge 218 is straight but disposed at an angle, a, inwardly over an initial segment 219. The inner edge 218 may also assume a curved shape, as shown in FIG. 3, that can have a shallow radius 222 or a sharper radius 224. It is noted that the radii 222 and 224 in the illustrated embodiment are both centered on the longitudinal axis L at different locations, but they can alternatively be off-centered. Together, the shallow and sharp radii 222 and 224 create concave, curved features within the staple 200, which can be used to engage various structures such as wires, channels for wires, and other structures typically fastened onto wooden poles. It is also noted that instead of one or both radii 222 and 224, the concave or curved features between the legs 204 may assume any other shape such as triangular, rectangular and the like. Advantageously, the increasing width W and decreasing distance D provide a double benefit—not only does the increasing width W increase the retention force of the staple 200 into the workpiece, for example, by increasing the friction holding the staple in its fastened position, but also the decreasing distance D is arranged to clamp objects fastened by the staple from one, two or three sides without the need for an insert, as has been the case in the past.

The outer edges 226 are shown straight, i.e., extending parallel to the axial direction L, but may alternatively be formed at a diverging angle from the inner edges 218 in a direction away from the tips 212. The outer edges 226 interface the two striking surfaces 45 along a radiused, convex surface 228. The convex surface 228 can have a large radius, as shown in FIG. 3, or a smaller radius, as shown in FIG. 4, depending on the staple application. For example, in staples that are installed using a power stapler such as the stapler 100 (FIG. 1), the concentrated and targeted application of the insertion force onto the striking surfaces 45 permits the increase of the radius of the surface 228, which decreases the size of the striking surfaces 45 and also saves on material.

In applications where staples may be installed by hand, for example, using a hammer, the radius may be sharper to increase the size of the striking surfaces as shown in FIG. 4. It should be appreciated, however, that staples having a larger radius such as the staple 200 shown in FIG. 3 is also suited for manual installation and, advantageously, is more tolerant to hammer hits that are not perfectly along the axial direction L due to the increased size of the convex surfaces 228. A depressed area 230 is formed along a length of the bridge 202 in a transverse direction, which is perpendicular to the longitudinal axis L, and at an offset height along the axial direction relative to the striking areas 45. The depressed area 230 helps focus or concentrate the impact loading onto the striking areas 45 during manual or automated installation of the staple 200 or 200′.

Other retention features to improve the retention of the staple into the work piece can also be used. For example, the staple 200 shown in FIGS. 2 and 3 includes a series of concave depressions 232 formed along the outer surfaces 226 and spaced at regular intervals spanning over the straight portion 216 and the tapered portion 220. The depressions 232 help retain the staple 200 into the work piece by providing concave depressions into which material from the workpiece, for example, pressure treated wood from a utility pole, may enter and help retain the staple 200 in place over time and under a wide variety of environmental conditions such as heat extremes, humidity, wetness, ice and the like. It is contemplated that any number of depressions 232 can be used, and that each depression 232 can take on any desired shape other than the circular shape shown in FIG. 3. For example, the depression can take on a triangular shape that is either symmetrical or skewed, to provide a fish-hook function of effect when the staple is installed. Examples of alternative depression designs are shown in FIG. 4, where a triangular depression 234 and a skewed depression 236 are illustrated.

All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

The use of the terms “a” and “an” and “the” and “at least one” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The use of the term “at least one” followed by a list of one or more items (for example, “at least one of A and B”) is to be construed to mean one item selected from the listed items (A or B) or any combination of two or more of the listed items (A and B), unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. The use of the term “configured” is to be construed to refer to structural shapes or specific forms that enable a specific purpose.

Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context. 

1. A staple, comprising: a first leg extending between a first tip and a first striking surface, the first leg having a width; a second leg extending between a second tip and a second striking surface; a bridge portion disposed between the first and second legs, the bridge portion disposed axially at a location between the first and second legs; wherein the width of the first leg generally increases over at least a portion of the first leg in an axial direction from the first tip towards the first striking surface.
 2. The staple of claim 1, wherein the first and second striking surfaces are coplanar.
 3. The staple of claim 1, wherein each of the first and second legs has an inner surface and an outer surface; wherein the outer surfaces of the first and second legs are parallel; and wherein the inner surfaces of the first and second legs are disposed in facing relation to define a distance therebetween that decreases along the axial direction in a direction towards the bridge portion.
 4. The staple of claim 2, wherein the first leg includes: a tapered portion disposed between the first striking surface and the first tip; wherein the inner edge of the first leg is disposed at an angle relative to the axial direction over at least a segment of the tapered portion.
 5. The staple of claim 4, wherein the first leg further comprises a straight portion having a uniform width along the axial direction, the straight portion disposed between the first tip and the tapered portion.
 6. The staple of claim 1, wherein the bridge portion defines a depressed area disposed between the first and second striking surfaces and offset therefrom in the axial direction.
 7. The staple of claim 1, wherein the body has a uniform thickness, T.
 8. The staple of claim 6, wherein the body is made from a punching operation applied to a metal plate material, and wherein the first or second tips are rounded or pointed.
 9. The staple of claim 1, wherein the body portion forms a concave cutout between the first and second legs adjacent the bridge portion.
 10. The staple of claim 1, further comprising one or more depressions formed along the outer surface of at least one of the first and second legs.
 11. The staple of claim 1, wherein the first and second legs have a different respective length in the axial direction.
 12. The staple of claim 1, wherein the first and second legs together have a generally rectangular cross sectional shape when viewed along the axial direction such that they are stackable with other body portions of a plurality of staples to form a stack, the stack being adapted for insertion into a fastener housing of a powered stapler.
 13. A staple, comprising: a body having first and second legs connected at a striking end, each of the a first and second legs extending between a respective tip and a respective striking surface at the striking end; each of the first and second legs having an inner surface and an outer surface, the inner surfaces converging at least partially along a length of each of the first and second legs such than a distance between the first and second legs gradually decreases over at least the portion of the body near the bridge portion; wherein the outer surfaces of the first and second legs are substantially parallel to one another and to the axial direction along said length.
 14. The staple of claim 13, wherein the first leg includes: a tip portion disposed opposite a striking surface; a straight portion disposed adjacent the tip portion; and a tapered portion disposed adjacent the straight portion; wherein the inner edge of the first leg is disposed at an angle relative to the axial direction over at least a segment of the tapered portion, and wherein the inner edge extends parallel to the axial direction over at least a segment of the straight portion.
 15. The staple of claim 13, wherein the body includes a depressed area disposed between the two striking surfaces, two striking surfaces being coplanar and generally located in aligned relation with the tips of the first and second legs in the axial direction.
 16. The staple of claim 13, further comprising one or more depressions formed along the outer surface of at least one of the first and second legs.
 17. A staple, comprising: a first leg extending between a first tip and a first striking surface; a second leg extending between a second tip and a second striking surface, the second leg being oriented such that the first and second tips are adjacent and the first and second striking surfaces are adjacent in an axial direction; a bridge extending between the first and second legs, the bridge axially disposed between the first and second tips and the first and second striking surfaces; wherein each of the first and second legs has an inner surface and an outer surface; wherein the inner surfaces of the first and second legs converge at an area near the bridge portion to define, together, concave features of different radii within the body between the first and second legs, the different radii being axially aligned.
 18. The staple of claim 17, wherein the first leg includes: a straight portion disposed adjacent the first tip; and a tapered portion disposed adjacent the straight portion opposite the first tip; wherein the inner edge of the first leg is disposed at an angle relative to the axial direction over at least a segment of the tapered portion, and wherein the inner edge extends parallel to the axial direction over at least a segment of the straight portion.
 19. The staple of claim 17, wherein the bridge includes a depressed area disposed between the first and second striking surfaces, the first and second striking surfaces being coplanar.
 20. The staple of claim 17, further comprising one or more depressions formed along the outer surface of at least one of the first and second legs.
 21. A staple, comprising: first and second legs extending substantially in parallel in an axial direction, each of the first and second legs extending between a respective tip and a respective striking surface; a bridge connected to the first and second legs between the two respective tips and the two respective striking surfaces; wherein the two respective striking surfaces are coplanar and perpendicular to the axial direction; wherein each of the first and second legs has an inner surface and an outer surface; wherein the outer surfaces of the first and second legs are parallel and perpendicular to the two respective striking surfaces; wherein the inner surfaces of the first and second legs are disposed in facing relation to define a distance therebetween that decreases along the axial direction in a direction towards the bridge portion.
 22. A staple, comprising: first and second legs, each of the first and second legs extending between a respective tip and a respective striking surface along an axial direction, the striking surfaces of the first and second legs being coplanar, wherein each of the first and second legs has a width; a bridge portion disposed between the first and second legs, the bridge disposed axially at a location between the striking surfaces and the tips of the legs; wherein the width of each of the first and second legs generally increases over a substantial length thereof in a direction towards the bridge portion. 